System and method of making an enhanced brake rotor with improved wear resistance

Abstract

Systems and methods of making an enhanced brake rotor having enhanced wear resistance are provided. The systems and methods provide a vehicular rotor comprising a base comprising iron (Fe). The base comprises an outer surface having a laser-hardened portion thereon. The laser-hardened portion comprises martensite and having a thickness of between 10 and 100 microns of the outer surface to define the enhanced brake rotor with enhanced wear resistance.

What is claimed is: 
     
       1. A method of making an enhanced vehicular brake rotor having enhanced wear resistance, the method comprising:
 providing a vehicular brake rotor comprising a base comprised of iron (Fe), the base comprising an outer surface having a target portion; 
 cleaning the brake rotor to remove contamination thereon; 
 laser-heating the target portion of the outer surface with a laser beam having an output of between 4000 Watts (W) and 9000 W to a temperature of between 800 degrees Celsius (° C.) and 1400° C., defining a laser-treated portion comprising austenite and having a pattern formed thereon by the laser beam; and 
 mass quenching the laser-treated portion to ambient temperature at a rate of about 270 degrees Celsius per second such that the austenite transforms to martensite to provide a laser-hardened portion comprising martensite, the laser-hardened portion having the pattern formed thereon and a thickness of between 10 and 100 microns of the outer surface, defining the enhanced brake rotor with enhanced wear and distortion resistance. 
 
     
     
       2. The method of  claim 1  further comprising ferritic nitrocarburizing the outer surface of the brake rotor to form a terrific nitrocarburized iron-nitride compound diffused therein for corrosion resistance. 
     
     
       3. The method of  claim 1  wherein the temperature of the target portion is between 900° C. and 1100° C. 
     
     
       4. The method of  claim 1  wherein the temperature of the target portion is 1020° C. 
     
     
       5. The method of  claim 1  wherein the laser beam has a laser velocity of between 6000 mm/s and 12,000 mm/s. 
     
     
       6. The method of  claim 1  wherein the laser beam has a laser velocity of between 8000 mm/s and 10,000 mm/s. 
     
     
       7. The method of  claim 1  wherein the output of the laser beam is between 4800 W and 5200 W. 
     
     
       8. The method of  claim 1  wherein the output of the laser beam is 5000 W. 
     
     
       9. The method of  claim 1  wherein the thickness of the laser-hardened portion is between 30 microns and 50 microns. 
     
     
       10. The method of  claim 1  wherein the thickness of the laser-hardened portion is 40 microns.